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NDE in Manufacturing and Life Management

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Instrumentation and signal and image processing. Miniaturisation (for example, MEMS/ NEMS) ... of sensors and instrumentation. Reference standards. Artificial ... – PowerPoint PPT presentation

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Title: NDE in Manufacturing and Life Management


1
NDE in Manufacturing and Life Management
Raw Materials Fabrication Pre-service inspection
In-service inspection Condition monitoring
Fracture mechanics Intelligent processing Damage
assessment Repair technology Life extension
Sensitivity Reliability Safety Quantification Char
acterisation
Defects Microstructure Stresses Properties
Sensors Instrumentation Signal image
processing Artificial intelligence
KBS Automation Robotics New techniques
procedures
2
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3
  • Visual
  • Dye penetrant
  • Magnetic particle
  • Radiography
  • (X, ? and Neutron)
  • Ultrasonic
  • Eddy current
  • Acoustic emission
  • Infrared thermography

Different NDT Techniques
4
Sensors Heart of the NDE techniques Physical
principles Sensitivity Calibration Ruggedness
(operating conditions) Selection (for example,
variety of ultrasonic sensors) Problem specific
design (for example, eddy current
sensors) Instrumentation and signal and image
processing Miniaturisation (for example, MEMS/
NEMS)
5
Codes, Standards and Specifications Procedures
for inspection Acceptance criteria Calibration of
sensors and instrumentation Reference
standards Artificial defects Natural
defects Forward and inverse modeling
6
Human Resource Development Training and
certification of personnel Various
Techniques Different Levels (I, II, III) National
Certification Board of Indian Society for
NDT Accreditation Standard procedures Bureau
of Indian Standards (IS-13805) International
Standards Organisation (ISO-9712) Quality manual
7
Nuclear reactors and other installations Reactor
vessels Feed water nozzles in BWR Core shrouds
in BWR Inspection of coolant channels (BARCIS)
end shields Steam generators and heat
exchangers Piping joints Concrete structures
and containment buildings Pumps Turbine
components Heavy water plant components Reproces
sing plants
8
Research Reactors (CIRUS, DHRUVA and FBTR) NDE
for life extension of CIRUS Reactor vessel,
piping and valves In service inspection of
FBTR Highly stresses joints in high temperature
sodium circuits (similar and dissimilar weld
joints) using ultrasonic testing Inspection of
sodium valves (consequent to sodium leakage)
using ultrasonic wall thickness gauging
9
Boiling water reactors (Tarapur) Inspection of
reactor vessel feed water nozzles using
ultrasonic testing Inspection of core shrouds
for detection of SCC using underwater visual
inspection and underwater ultrasonic
testing Inspection of pump castings using
In-situ metallography Infrared thermography for
inspection of electrical installations
10
Pressurised Heavy Water Reactors Inspection of
end shields using ultrasonic testing and acoustic
emission testing for cracks and leaks BARCIS for
comprehensive inspection of coolant channels
(ultrasonic and eddy current testing) Detection
of fine scratches in calandria tubes (en-mass
coolant channel replacement programme) Special
focussed eddy current probe designed, developed
and patented Detection of leaking coolant
channel using acoustic emission testing and
advanced signal analysis methodologies Eddy
current testing of tubes of moderator heat
exchangers, steam generators etc. Development of
acoustic resonance technique for detection of
leaks with high sensitivity and speed
(patented) Structural integrity assessment of
ring beam of containment structure of KAIGA plant
using impact echo testing Inspection of steam
turbine blades with high sensitivity fluorescent
magnetic particle testing for defects and XRD
based fatigue damage assessment Inspection of
17-4 PH steel ram heads of fueling machines using
precision radiography
11
Prototype Fast Breeder Reactor Design for
inspection (fabrication and in service) Enhanced
detection sensitivity for defects in austenitic
stainless steel welds using advanced ultrasonic
inspection methodologies Reliable inspection of
fuel cladding tubes Ultrasonic and eddy current
testing (Complementary) Inspection of
ferromagnetic tubes and tube to tube sheet weld
joints of steam generators Saturation
magnetisation eddy current testing Microfocal
radiography, videoimagescopy and
replication Ultrasonic Internal rotary
inspection system Remote field eddy current
testing with wavelet transform based analysis)
Real time radiography of thermocouples Robot
based inspection system for main vessel and
safety vessel (visual, Eddy current for weld
centre line, ultrasonic for welds) Data
management software
12
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13
Heavy water plants Integrity assessment and life
extension of conical inlet of a heavy water plant
using ultrasonic, in-situ metallography and
hardness methods Acoustic emission monitoring
during hydro testing of waste stripper for
structural integrity assessment Inspection of
ammonia cracker tubes made of Inconel
625 Development of ultrasonic velocity based
method for monitoring microstructural degradation
in service and also to qualify rejuvenation
process Inspection of steam generators and heat
exchangers Inspection of piping
14
Reprocessing plants Laser based profilometry
and ultrasonic inspection of dissolver
vessels EMAT based guided ultrasonic wave
inspection Remote visual inspection of waste
vault
15
SUMMARY OF APPLICABILITY AND CAPABILITY
OF VARIOUS NDT TECHNIQUES USED FOR ASSESSMENT OF
DEFECTS IN MATERIALS AND COMPONENTS
METHOD MATE-RIALS APPLI-CABLE APPLICABLE COMPONENT GEOMETRIES APPLICABLE COMPONENT GEOMETRIES DETECTION CAPABILITY DETECTION CAPABILITY DETECTION CAPABILITY DYNAMIC DETECT-ION _at_ DEFECT SIZING DEFECT SIZING DEFECT CHARACTE-RIZATION NUMERICAL MODELLING
METHOD MATE-RIALS APPLI-CABLE Linear Non-linear Surface Sub- surface Internal DYNAMIC DETECT-ION _at_ Length Orien-tation DEFECT CHARACTE-RIZATION NUMERICAL MODELLING
VI A Y Y Y N N N Y N Y N
LPI A Y Y Y N N N Y N Y N
MPI M Y Y Y N N Y N Y
ACPD E Y Y Y N N N Y N Y
DCPD E Y Y Y Y N N Y Y
UT A Y Y Y Y Y N Y Y Y Y
ECT E Y Y Y Y Y1 N Y Y1 Y Y
RT A Y Y Y Y Y N Y Y Y Y
AET A Y Y Y Y Y Y Y N 2 N
IRT A Y Y Y Y Y Y Y
MFLT M Y Y Y Y Y N Y N N Y
Y POSSIBLE N NOT POSSIBLE - FEASIBILITY
EXISTS A ALL MATERIALS E ONLY ELECTRICALLY
CONDUCTIVE MATERIALS M ONLY MAGNETIC
MATERIALS 1 LESS THAN 6 mm 2 ONLY HARMFUL
(GROWING DEFECTS)
_at_ - DETECTED AS AND WHEN DEFECT INITIATES AND
GROWS VI VISUAL INSPECTION LPI LIQUID
PENETRANT INSPECTION MPI MAGNETIC PARTICLE
INSPECTION PD POTENTIAL DROP TECHNIQUE (AC AND
DC) UT ULTRASONIC TESTING
ECT EDDY CURRENT TESTING RT RADIOGRAPHY AET
ACOUSTIC EMISSION TESTING IRT INFRARED
THERMOGRAPHY MFLT MAGNETIC FLUX LEAKAGE
TECHNIQUE
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